Arrangement and method for automatically determined time constant for a control device

ABSTRACT

An arrangement for use in connection with an air handling unit includes a controller and a processing circuit. The controller is configured to control a device within an air handler unit, which includes at least a first coil. The processing circuit is configured to receive first information representative of a maximum liquid flow rate through the first coil and second information representative of a maximum air flow rate of the first coil. The processing circuit is further configured to generate a time constant estimate, based on the first information and second information, for use in the controller in performing control of the device.

This application claims the benefit of U.S. provisional patentapplication Ser. No. 60/731,889, filed Oct. 31, 2005 and which isincorporated herein by reference.

FIELD OF THE INVENTION

The invention relates generally to control arrangements in an airhandling unit of a building system, particularly those that require timeconstants for performing control operations.

BACKGROUND

Control arrangements are used in a variety of applications, includingbut not limited to various elements of a building comfort system, orheating, ventilation, air conditioning (“HVAC”) system. One devicewithin an HVAC system is an air handling unit.

An air handling unit is typically known as a device that blows heated orchilled air through the ventilation system of a building. A typical airhandling unit includes a fan (or other air moving device) and heatingand/or cooling coils. The coils are designed to receive a heatingmaterial such as steam or hot water, or cooling material such as chilledwater or other coolant. The coils thus heat or chill the air as neededbefore it is blown through the ventilation system. In summer, the airhandling unit may blow cool air through the ventilation system byreceiving chilled water into a coil and then drawing the air to be blownover the coil. In winter, the air handling unit blows heated air throughthe ventilation system by receiving heated water or steam into a coiland then drawing the air to be blown over the coil.

As with many devices that operate within a building system, the airhandling unit is a dynamic system. In any dynamic system, there is atransition time between its input and output signals. The transitiontime it takes for the output to reach about 63% of its steady-statevalue due to a step change in the input is called Time Constant. In adynamic system where the output always needs some transition time toreach its steady state, there will always be a Time Constant. Forexample, if a heating system can respond to a step input to raise thetemperature of a house by 3 degrees, then the time constant is the timeit takes for the house to change by 3 times 63% or 1.89 degrees.

In addition to the time constant, other parameters that express thedynamics of a physical system are known as the static gain and delaytime. The static gain, time constant, and delay time together provideinformation that allow a controller such as a PID or PI controller to betuned. Tuning controllers based on the static gain, time constant, anddelay time of the physical system to be controlled is known in the art.

Thus, when a control system is being initially configured or installed,it is advantageous to obtain the static gain, time constant, and delaytime of that system so that the controller may be properly tuned. Whilesome known advanced control schemes can adapt to the changes inoperating conditions, they still often require some initial settingsincluding at least a time constant for the system.

In order to obtain the time constant of a particular device, specifictests on the device, such as a “bump” test, are performed. One type ofbump test providing a step value input is provided to a device orsystem, which eventually causes the system to change from an initialmeasurable output A to a final measurable output B. The time of thetransition from output A to output B is measured, with the time constantbeing identified as the time it takes for the device or system output toachieve 63.1% of the change from output A to output B.

Such bump tests have often been used to determine the time constantsassociated with the supply air temperature control processes of an airhandling unit. As is known in the art, a typical air handling unit mayalter the temperature of the supply air in a number of ways, includingusing heating and/or cooling coils, or admitting more (cooler or warmer)outside air into the building. Each of those supply air temperaturecontrol processes has its own time constant. Prior art bump testsinvolve forcing the air handling unit to change the temperature usingeach of these processes, and determining the response time.

Bump tests have a disadvantage in that they are relatively timeconsuming, are labor intensive, and require technical expertise. Thesystem is typically tested after installation. Thus, costly tests andexpertise are needed on a job-site to program parameters into a controlsystem that involves an air-handling unit.

There is a need, therefore, for a method or apparatus that reduces theamount of testing and expertise required to develop a time constantestimate for an air handling unit.

SUMMARY OF THE INVENTION

At least some embodiments of the invention address the above-describedneeds, as well as others, by providing a method of automaticallycalculating a time constant for an air handling unit subsystem, and oran arrangement that automatically calculates and uses a time constant inconnection with an air handling unit control system.

A first embodiment of the system is an arrangement that includes acontroller and a processing circuit. The controller is configured tocontrol a device within an air handler unit, which includes at least afirst coil. The processing circuit is configured to receive firstinformation representative of a maximum liquid flow rate through thefirst coil and second information representative of a maximum air flowrate of the first coil. The processing circuit is further configured togenerate a time constant estimate, based on the first information andsecond information. The time constant is used in the controller inperforming control of the device.

The above described features and advantages, as well as others, willbecome more readily apparent to those of ordinary skill in the art byreference to the following detailed description and accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a portion of an exemplary HVAC system that includes an airhandling unit which may be controlled in accordance with one or moreembodiments of the invention;

FIG. 2 shows in further detail an exemplary embodiment of the airhandling unit of FIG. 1;

FIG. 3 is a block diagram illustrating schematically an air handlingunit supply air process with a 1-input-3-output (1×3) model-freeadaptive (MFA) controller that controls a 3-input-1-output (3×1) systemwith three actuators.

FIG. 4 is a block diagram illustrating schematically a 1-input-3-output(1×3) model-free adaptive (MFA) control arrangement that controls thesupply air temperature of an air handling unit comprising a damper, aheating actuator, a cooling actuator, a heating coil, a cooling coil,and a temperature sensor.

FIG. 5 is a block diagram illustrating schematically a 1-input-2-output(1×2) model-free adaptive (MFA) control arrangement that controls thesupply air temperature of an air handling unit comprising a damper, aheating actuator, a heating coil, and a temperature sensor.

FIG. 6 is a block diagram illustrating schematically a 1-input-2-output(1×2) model-free adaptive (MFA) control arrangement that controls thesupply air temperature of an air handling unit comprising a damper, acooling actuator, a cooling coil, and a temperature sensor.

FIG. 7 is a block diagram illustrating a 1-input-2-output (1×2)model-free adaptive (MFA) control arrangement that controls the supplyair temperature of an air handling unit comprising a heating actuator, acooling actuator, a heating coil, a cooling coil, and a temperaturesensor.

FIG. 8 is a block diagram illustrating a single-input-single-output(SISO) model-free adaptive (MFA) control arrangement that controls asingle-input-single-output (SISO) system comprising an actuator, aprocess, and a sensor.

FIG. 9 shows an exemplary method for estimating time constants forsupply air temperature control in accordance with exemplary embodimentsof the invention;

FIG. 10 shows an exemplary embodiment of a computing apparatus that maybe used to determine supply air temperature control time constants inaccordance with embodiments of the invention;

FIG. 11 shows an exemplary set of steps that may be carried out by thecomputing apparatus of FIG. 10 to determine supply air temperaturecontrol time constants of an air handling unit.

DETAILED DESCRIPTION

FIG. 1 shows a portion of an exemplary HVAC system 100 that includes anair handling unit 108 which may be controlled in accordance with one ormore embodiments of the invention. The portion of the HVAC system 100illustrated in FIG. 1 includes a supply duct 102, a return path 104, afirst room damper system 106, and an air handling unit 108. The HVACsystem 100 provides heated, chilled and/or fresh air throughout abuilding having a multiplicity of zones, spaces and/or rooms. In FIG. 1,only a first room 110 is shown for purposes of clarity of exposition.However, it will be appreciated that the facility or building maycontain several other rooms, spaces and or zones, and that the HVACsystem 100 will contain several other elements known in the art.

The air handler unit 108 is a device that advances air flow through someor all of the HVAC system 100. Some buildings have multiple air handlingunits. The air handler unit 108 of FIG. 1 includes a supply fan 112, asupply air outlet 114, a fresh air inlet 116, an exhaust 118, a buildingreturn inlet 120, a recirculation damper 122, an exhaust damper 124, anoutdoor damper 126, a heating coil 128 and a cooling coil 130. In thisembodiment, the supply fan 112 is upstream of, and in fluidcommunication with, the supply air outlet 114. The supply air outlet 114interfaces to the supply duct 102 of the system 100. The cooling coil130 is upstream of, and in fluid communication with, the supply fan 112,and the heating coil 128 is upstream of the cooling cool 130.

The outdoor inlet 116 is in fluid communication with the outdooratmosphere, and serves as a source of fresh air to the HVAC system 100.The outdoor inlet 116 is located upstream of the heating coil 128 (andthus also the supply fan 112) and is connected to the heating coil viathe outdoor air damper 126.

The building return inlet 120 is connected to the return path 104 of thebuilding. The return path 104, which may suitably be the plenum spaceabove building ceilings, extends throughout the building and isconfigured to receive “spent” or exhaust air from various rooms andspaces. The building return inlet 120 is upstream of both the buildingexhaust 118 and the heating coil 128. The building return inlet 120 isin fluid communication with the building exhaust 118 via the exhaustdamper 124, and is in fluid communication to the heating coil 128 viathe recirculation damper 122. The building exhaust 118, like the outdoorair inlet 116, is in fluid communication with the outdoor atmosphere.However, the building exhaust 118 provides an egress port for spent orstale air from the building.

In general, the air handling unit 108 is operable to supply air to thesupply duct 102. The supplied air may be heated, chilled, and mayinclude some mixture of fresh air and recirculated air. The air handlingunit 108 supplies chilled air when the temperature of relevant portionsof the building needs to be lowered, and supplies heated air when thetemperature of relevant portions of the building needs to be raised.However, in some cases, other heating and cooling elements may be usedto effect temperature changes in localized areas, even though thoseareas are coupled to receive air heated or chilled by the air handlingunit 108.

The supply air flows from the air handling unit 108 through the supplyduct 102, and may be tapped off at various portions of the building,including by way of example, the first room 110. The supply duct 102 iscoupled to the first room 110 via a ventilation damper 106. Other roomsand areas, not shown, are coupled to receive supply air from the supplyduct 102 in a similar manner. The ventilation damper 106 is used toregulate the amount of supply air that is provided to the room 110. Theamount of heated or chilled supply air that is provided to the room 110is dependent upon the sensed temperature of the room 110, the desiredtemperature of the room 110, the temperature of the supply air in thesupply duct 102, the air flow in the supply duct 102, and the need forfresh air in the room 110. Control systems that determine the positionand operation of the ventilation damper 106 are well known in the art.

The supply air provided to the various rooms and spaces of the buildingcreates the need to return exhaust air via the return path 104. Eachroom or space is operably connected to provide exhaust air to the returnpath 104. (See e.g., the room 110). The return path 104 provides thereturn air to the outdoor exhaust 118, back to the heating coil 128 forrecirculation, or a combination of both. The amount of exhaust air thatis recirculated, and the amount that exits via the building exhaust 118,is controlled by the dampers 122 and 124.

The outdoor air inlet 116 provides air to the heating coil 128 invarying degrees, depending on the amount of exhaust air that isrecirculated via recirculation damper 122. The mix of recirculatedexhaust air and fresh outdoor air that is provided to the heating coil128 (and thus to the cooling coil 130 and supply fan 112) is controlledby the recirculation damper 122 and the outdoor air damper 126.

The heating coil 128 is a device that is operable to perform a heatexchange between a heating medium such as water or steam, and the airflowing to the supply fan 112. To this end, the heating coil 128 has aconduit configured to receive a liquid or steam heating medium. Thisconduit, not shown, is disposed in a heat exchange area. Such devicesare known in the art. The heating coil 128 has an associated valveactuator, not shown in FIG. 1, that controls the flow of the heatingmedium into the coil 128. Thus, when heating is needed, the heatingmedium is allowed to advance into the heating coil 128. The heatexchange takes place through the transfer of heat from the heatingmedium to the supply air being drawing through the coil 128 by thesupply fan 112.

The cooling coil 130 is a device operable to perform a heat exchangebetween a cooling medium such as liquid coolant, and the air flowing tothe supply fan 112. Like the heating coil 128, the cooling coil 130 hasan associated valve actuator, not shown in FIG. 1, that controls theflow of the cooling medium into the coil 130. Thus, when cooling isneeded, the cooling medium is allowed to advance into the cooling coil130. The heat exchange may then take to transfer heat from the supplyair, thereby cooling the supply air.

In operation, the air handling unit 108 is associated with, or contains,a controller that controls the operation of the dampers 122, 124 and126, and operation of the coils 128 and 130. The controller, which mayfor example be the controller 150 of FIG. 2, discussed below, controlsthe dampers 122, 124 and 126 and the coils 128 and 130 to selectivelyheat or chill the supply air that is provided to the supply duct 102 bythe supply fan 112. For example, if the supply air must be warmer, thenthe heating coil 128 may be filled with the heating medium (steam or hotwater). If the outside air temperature is warmer than the exhaust air,then the dampers 122, 124 and 126 may be manipulated to allow moreoutside air into the mixture that becomes the supply air.

Various schemes for controlling the supply air temperature are known,using dampers configured as shown in FIG. 1, and using heating andcooling coils as shown in FIG. 1. These schemes include PI control, PIDcontrol and even adaptive controls such as the MFA control scheme taughtin U.S. patent application Ser. No. 10/857,520, published as U.S. PatentPublication No. 2005/0004687, which is incorporated herein by reference.An example of another control scheme based on ordinary PI control thatis adapted for an air handling unit is shown in U.S. Pat. No. 5,791,408,which is incorporated herein by reference.

As discussed further above, one feature of each of the above referencedcontrol schemes is that they must be at least roughly tuned to thephysical system of the air handling unit. As is known in the art, propertuning of the control feedback algorithms usually requires at least anestimate of the gain of the system and the time constant of the physicalsystem being controlled. In accordance with aspects of the presentinvention, the time constants for the supply air temperature controlprocesses are determined using system specifications and, in some cases,reasonable estimation. Thus, complex testing, such as “bump” testing, isnot required to determine the system time constants relating to supplyair temperature control.

The determination of the system time constants as described herein isparticularly useful in connection with an MFA controller as taught byU.S. patent application Ser. No. 10/857,520. In that controller, thegain is automatically tuned by the MFA controller, and therefore may beset with an initial arbitrary value, for example, the value of 3.Accordingly, to prepare an MFA controller designed for the AHU 108 ofFIGS. 1 and 2, a time constant estimated using the techniques describedherein and the arbitrary gain value (e.g. 3) may be provided to the MFAcontroller. The controller 150 would then be effectively ready foroperation without bump testing.

FIG. 2 shows in further detail an exemplary embodiment of the airhandling unit 108 that shows more of the control circuits and elementsthat manipulate the dampers 122, 124 and 126 and the heating and coolingcoils 128 and 130, respectively. Like elements from FIG. 1 will havelike reference numbers.

As shown in FIG. 2, the air handling unit 108 further contains a returnfan 113, a controller 150, a number of sensors that provide feedbackinformation to the controller 150, and a number of actuators that effectsystem outputs responsive to control signals generated directly orindirectly by the controller 150. The sensors of the air handling unit108 include a return flow sensor 152, a return air temperature andhumidity (“T&H”) sensor 154, a supply T&H sensor 156, a supply flowsensor 158, an outdoor inlet flow sensor 160, and an outdoor T&H sensor161. The actuators of the air handling unit 108 include a set of damperactuators 162, a heating coil valve actuator 164 and a cooling coilvalve actuator 168.

The return flow sensor 152 is arranged in the proximity of the returnair inlet 120 to measure the flow of the exhaust air. The return airtemperature sensor 154 is arranged in the same area, in order to obtaina measure of the exhaust air temperature. The supply temperature sensor156 is generally affixed at the supply air outlet 114, downstream of thesupply fan 112, the heating coil 128 and the cooling coil 130. Thesupply flow sensor 158 is similarly situated to measure the supply airflow downstream of the supply fan 112. The outdoor inlet flow sensor 160is disposed just down stream of the outdoor air damper 126 and theoutdoor air temperature sensor 161 is situated just upstream of theoutdoor air damper 126, near the outdoor air inlet 116.

The set of damper actuators 162 are operably connected to control theposition of the outdoor air damper 126, the exhaust damper 124, and therecirculation damper 122. The heating coil valve actuator 164 isoperably connected to control the flow of the heating medium (e.g. hotwater or steam) into (i.e. through) the heating coil 128, and thecooling coil valve actuator 168 is operably connected to control theflow the cooling medium into the cooling coil 130.

The air handling unit 108 thus includes many devices having variousprocess outputs. Many of the functions of the air handling unit 108 areknown in the art and discussion thereof is not necessary for expositionof the invention. However, common controlled processes of the airhandling unit 108 include control of the static pressure in the supplyduct 104, control of the return air flow in the return air inlet 114,and control of the supply air temperature TS. Control schemes fordetermining and regulating such variables are known in the art, and varyfrom building to building. In general, the air handling unit 108receives set points for supply duct static pressure and/and or returnair flow, as well as for supply air temperature. These set points aretypically generated in coordination with other control processes in thebuilding, as is known in the art.

The supply duct air pressure is controlled, at least in part, bycontrolling the supply fan 112. The controller 150 uses feedback fromthe supply flow sensor 158 as well as other information to determinewhether the supply duct air pressure is at or near a desired point. Thereturn air fan 113 is used to control the return air flow. Feedback fromthe return air flow sensor 152 is used to determine whether the returnflow is at or near a desired value. Various methods for controlling thesupply fan 112 and return fan 113 are known, and not provided in detailherein.

In a similar manner, the air handling unit 108 controls the supply airtemperature such that the temperature detected by the supply airtemperature sensor 156 is near or equal to a desired supply airtemperature. The supply air temperature may be altered by appropriatelymanipulating the actuators 164, 168 and the damper actuators 162 toachieve or nearly achieve a desired supply temperature. In general, thesupply air temperature TS may be increased by adding warmer outside air,or operating the heating coil 128. The supply air temperature TS may bedecreased by adding cooler outside air, or operating the cooling coil130.

Thus, the controller 150 uses these processes, and typically a mixtureof these processes, to control the temperature of the supply air. Asdiscussed above, there are various methodologies for controlling theseprocesses using feedback provided by the supply air temperature sensor156.

The model of the overall supply air temperature control process isgenerally shown in FIG. 3. The example of FIG. 3 employs an MFAcontroller 210. Since the building types, sizes, climate, seasons,loads, and environment vary, the supply air temperature process can benonlinear and have a varying process static gain, time constant, anddelay time. To control this complex process, PID(proportional-integral-derivative) type of controllers must be eithertuned to a compromised set of parameters or frequently re-tuned.Model-Free Adaptive (MFA) controllers as described in U.S. Pat. No.6,055,524, U.S. Pat. No. 6,556,980, U.S. Pat. No. 6,360,131, U.S. Pat.No. 6,684,115 B1, U.S. Pat. No. 6,841,112 B1, U.S. application Ser. No.10/857,520, have the ability to adapt to changing conditions. Thus, theMFA based AHU control system provides consistent control performance inall operating conditions and does not require manual tuning or re-tuningof the controller parameters.

However, it will be appreciated that the same process may be implementedwith a PI or PID controller, provided that another method is used toestimate or obtain the system gain.

In a typical system such as the AHU 108 of FIG. 1, we can consider thatthere are three sub-processes in a supply air temperature controlsystem: the damper process, heating process, and cooling process. Theheating process uses the various elements, including the heating coil128, to generate heated supply air. The cooling processing uses variouselements, including the cooling coil 130, to generate cooled or chilledsupply air. The damper process involves manipulating the dampers 122,124 and 126 to increase or decrease the proportion or ratio of outsideair to recycled air.

In the MFA controller embodiment, there are four primary parameters forconfiguring the controller 150 for the supply air temperature:controller gain, damper time constant, heating time constant, andcooling time constant. Since the Model-Free Adaptive (MFA) controllershave strong adaptive capabilities and wide robust ranges, the controllergain can be set using a default value and the process time constants canbe entered using roughly estimated values. As will be discussed below,the process time constant for the heating, cooling, and damper processesmay be automatically determined based on the maximum or design air flowrate and the maximum or design water flow rate which are readilyavailable in the AHU design documents and computer database. The processtime constant may be used for other purposes, such as in another type ofcontroller.

Without having to build process mathematical models or perform processbump tests, the techniques described below are also useful forautomatically estimating the time constant parameters for otherprocesses such as the mixed air temperature for the MFA controllers usedfor AHU control so that such MFA controllers can be automaticallyconfigured and launched without human interaction.

Multi-Input-Single-Output (MISO) MFA Control System

FIG. 3 shows a schematic of a general AHU control system 200 thatincludes a controller, process devices, and a system.

As illustrated in FIG. 3, a 3-input-1-output (3×1) MFA control systemcomprises a 1-input-3-output (1×3) MFA controller 210, a3-input-1-output (3×1) process 212, actuators A₁ 218, actuator A₂ 220,actuator A₃ 222, and signal adders 214, 216. By way of example, theactuator A₁ 218 may be the actuator 162 of FIG. 2. Similarly, theactuator A₂ 220 may be the actuator 164 of FIG. 2, and the actuator A₃222 may be actuator 168 of FIG. 2. The process may suitably be the airflow process through the various elements of the air handling unit 108shown in FIG. 2. The value of x(t) may suitably be obtained by thetemperature sensor 156 of FIG. 2.

The signals shown in FIG. 1 are as follows:

r(t)—Setpoint.

y(t)—Process Variable, y(t)=x(t)+d(t).

x(t)—Process Output.

V₁(t)—Controller Output 1 to manipulate Actuator A₁.

V₂(t)—Controller Output 2 to manipulate Actuator A₂.

V₃(t)—Controller Output 3 to manipulate Actuator A₃.

d(t)—Disturbance, the disturbance caused by noise or load changes.

e(t)—Error between the Setpoint and Measured Variable, e(t)=r(t)−y(t).

The control objective is for the controller 210 to produce outputsV₁(t), V₂(t) and V₃(t) to manipulate actuators A₁, A₂ and A₃ so that themeasured variable y(t) tracks the given trajectory of its setpoint r(t)under variations of setpoint, disturbance, and process dynamics. As willbe discussed below, the controller 210 generates the outputs based ontuning provide at least in part by a time constant for the system 212that is generated in accordance with one or more embodiments of theinvention.

FIGS. 4 through 8 show exemplary embodiments and variants of the generalcase of FIGS. 2 and 3, including those with more or less actuator and/orsub-processes.

3-Input-1-Output (3×1) MFA Control System for Air Handling Unit

FIG. 4 is a block diagram illustrating a 3-input-1-output (3×1) MFAcontrol system that comprises a 1-input-3-output (1×3) model-freeadaptive (MFA) controller 224, a 3-input-1-output (3×1) supply airtemperature process of the air handling unit 238, and signal adders 240,242. The supply air temperature process 238 further comprises a damper226, a heating actuator 228, a cooling actuator 230, a heating coil 232,a cooling coil 234, and a temperature sensor 236. The example of FIG. 4fairly represents the control schematic for the supply air process forthe air handling unit 108 of FIG. 2.

As discussed further above, the supply air process may be represented asthree subprocesses in this embodiment, a damper process, a heatingprocess, and a cooling process. Each subprocess corresponds to thedevice actuator that is controlled. For example, in the damper process,the damper actuator 226 receives an actuator control signal V1, and inthe cooling process, the cooling actuator 230 receives the actuatorcontrol signal. Each subprocess has its own time constant owing to thearchitecture of the air handling unit, wherein air may flow throughmultiple devices other than the device that is being controlled. Forexample, in the heating process, the heating actuator 228 receives theactuator signal, but the time constant is affected by the heatingactuator time constant, the heating coil time constant, the cooling coiltime constant, and the temperature sensor time constant. (See e.g.,architecture of the AHU 108 of FIG. 2).

The signals shown in FIG. 4 are as follows:

Tsu SP—Setpoint of the supply air temperature.

Tsu PV—Process Variable of the supply air temperature, Tsu PV=x(t)+d(t).

x(t)—Process output.

V₁—Controller output 1 to manipulate the damper 226.

V₂—Controller output 2 to manipulate the heating actuator 228.

V₃—Controller output 3 to manipulate the cooling actuator 230.

d(t)—Disturbance, the disturbance caused by noise or load changes.

e(t)—Error between the Setpoint and Process Variable, e(t)=Tsu SP−TsuPV.

The control objective is for the controller to produce outputs V₁, V₂and V₃ to manipulate the actuators so that the Process Variable of thesupply air temperature tracks the given trajectory of its Setpoint undervariations of setpoint, disturbance, and process dynamics. It is notedthat the “signal” lines between elements within the air handling unit238 represent the supply air flow itself, not electrical signals.

For this 1-input-3-output (1×3) model-free adaptive (MFA) controller,there are four important controller parameters as follows:

K_(c)—Controller gain,

T_(cd)—Damper process time constant,

T_(ch)—Heating process time constant,

T_(cc)—Cooling process time constant.

Since the Model-Free Adaptive (MFA) controller 224 is adaptive, thecontroller gain K_(c) can be set using a default value and no manualtuning of this parameter is required after the controller 224 islaunched. For instance, we can set K_(c)=3 as the default value whenconfiguring the MFA controller 224. On the other hand, the timeconstants T_(cd), T_(ch), and T_(cc) need to be set relativelyaccurately since they are related to the dynamic behavior of the damper,heating, and cooling processes. In the embodiment described herein, eachof the time constants T_(cd), T_(ch), and T_(cc) is estimated at leastin part based on physical parameters of the system, such as the maximumhot water flow rate through the heating coil 232 and/or the maximumchill water flow rate through the cooling coil 234.

In building automation applications, the size of the air handling unit238 including the damper(s) 226, heating coil 228, and cooling coil 230is designed based on the volume of the building space that the AHUsystem services and the thermal load on the building space. Theinformation about the maximum or the design air flow rate, hot waterflow rate, and chill water flow rate is readily available in the designdocument and saved in a computer database. Therefore, time constantsbased on the AHU design information can be automatically generated forthe MFA controller configuration procedure to save time and manpower.

In this embodiment, it is advantageous to estimate the time constantsfor damper, heating process, and cooling process based on the followingformulas: $\begin{matrix}{{T_{c\quad d} = {T_{{damper}\quad{actuator}} + T_{{heating}\quad{coil}} + T_{{cooling}\quad{coil}} + T_{{temp}\quad{sensor}}}},} & (1) \\{{T_{ch} = {T_{{heating}\quad{actuator}} + T_{{heating}\quad{coil}} + T_{{cooling}\quad{coil}} + T_{{temp}\quad{sensor}}}},} & (2) \\{{T_{cc} = {T_{{cooling}\quad{actuator}} + T_{{cooling}\quad{coil}} + T_{{temp}\quad{sensor}}}},} & (3) \\{{T_{{heating}\quad{coil}} = {c_{1}\frac{F_{air}}{F_{hw}}}},} & (4) \\{{T_{{cooling}\quad{coil}} = {c_{2}\frac{F_{air}}{F_{cw}}}},} & (5)\end{matrix}$where

T_(cd)—Damper process time constant,

T_(ch)—Heating process time constant,

T_(cc)—Cooling process time constant,

T_(damper actuator)—Stroke time of the damper actuator,

T_(heating actuator)—Stroke time of the heating actuator,

T_(cooling actuator)—Stroke time of the cooling actuator,

T_(temp sensor)—Time constant of supply air temperature,

T_(heating coil)—Time constant of the heating coil,

T_(cooling coil)—Time constant of the cooling coil,

F_(air) 13 Maximum or design air flow rate,

F_(hw)—Maximum or design hot water flow rate,

F_(cw)—Maximum or design chill water flow rate,

c₁—Constant depending on the units of F_(air)and F_(hw),

c₂—Constant depending on the units of F_(air) and F_(cw).

As illustrated in the example AHU 108 of FIGS. 1 and 2, there areusually three dampers in an AHU system: outside air damper (OAD), returnair damper (RAD), and exhaust air damper (EAD). (See dampers 126, 122and 124, respectively, of FIGS. 1 and 2). Most of the time the threedampers work in unison with the return air damper opening as the exhaustand outside air dampers close. Basically, the system is either bringingin outside air and exhausting an equivalent amount, or it isrecirculating the inside air, or doing something in between usingintermediate positions. These three dampers are sometimes referred to asmixed air dampers. From a control system point of view, we can treatthem as only one damper, e.g. damper 226 of FIG. 4 that the controlleroutput manipulates.

The damper time constant by itself is small in value—typically it equalsdamper actuator stroke time plus the temperature sensor time constant.However, since the air from the three dampers must go through theheating and cooling coils before reaching the supply air temperaturesensor, the time constants for the heating coil and cooling coil need tobe added to estimate the overall time constant for the damper process.This explains how Equation (1) is derived.

In this AHU system 238, it is assumed that the heating coil ispositioned before the cooling coil. Thus, similar to the example of FIG.2, the air flow goes through the heating coil 228 first, the coolingcoil 234 next, and then reaches the supply air temperature sensor 236.Therefore, the heating process time constant, as shown in Equation (2),can be estimated based on the stroke time of the heating actuator 228,and the time constants of the heating coil 232, cooling coil 234, andthe temperature sensor 236. The cooling process time constant, as shownin Equation (3), can be estimated based on the stroke time of thecooling actuator 230, and the time constants of the cooling coil 234,and the temperature sensor 236. Notice that the heating coil 232 isomitted in this case because it is located before the cooling coil 234.In case the cooling coil 234 is positioned before the heating coil 232,the heating and cooling formulas can be changed accordingly. Thisconcept applies throughout this description.

In a liquid-to-air type heat exchanger, as the hot media such as hotwater goes through the coil of a heating exchanger or heating coil 232,the surrounding air is warmed as the heat is transferred from water toair. As chilled media goes through the coil of a cooling exchanger orcooling coil 234, the surrounding air is cooled as the heat istransferred from air to water. The time constant of the heating coil 232or cooling coil 234 is related to the heat-transfer area, the specificheat of the liquid, heat-transfer coefficient, and weight of the liquid.While such information may be used to obtain an accurate time constant,the information mentioned above is not typically readily available.

As an alternative, the equations (4) and (5) are derived based on theavailable AHU design information. An example of such a derivation isprovided below in detail. In the discussion below, it is noted that theunit for all time constant values is in seconds.

There are many types and sizes of damper actuators, heating actuators,and cooling actuators. There could also be variations in temperaturesensors used for measuring the supply air temperature. In many cases,the time constant of the actuators can be based on an estimate (ormeasurement of) of the stroke time for the actuators. A suitableestimate is 30 second. Similarly, time constant for the temperaturesensor to be 30 seconds. Then, Equations (1) to (3) can be simplified toEquations (6) to (8), respectively.T _(cd) =T _(heating coil) +T _(cooling coil)+60,  (6)T _(ch) =T _(heating coil) +T _(cooling coil)+60,  (7)T _(cc) =T _(cooling coil)+60,  (8)

In the U.S. customary system, air flow rate is based on cubic feet perminute and water flow rate is based on gallons per minute. Then,Equations (4) and (5) can be converted to the following formula,respectively: $\begin{matrix}{{T_{{heating}\quad{coil}} = {0.02\frac{F_{air}}{F_{hw}}}},} & (9) \\{{T_{{cooling}\quad{coil}} = {0.25\frac{F_{air}}{F_{cw}}}},} & (10)\end{matrix}$where

T_(heating coil)—Time constant of the heating coil in seconds,

T_(cooling coil)—Time constant of the cooling coil in seconds,

F_(air)—Maximum or design air flow rate in cubic feet per minute,

F_(hw)—Maximum or design hot water flow rate in gallons per minute,

F_(cw)—Maximum or design chill water flow rate in gallons per minute.

In the international metric system, both air flow rate and water flowrate are based on liters per second. Then, Equations (4) and (5) can beconverted to the following formula, respectively: $\begin{matrix}{{T_{{heating}\quad{coil}} = {0.15\frac{F_{air}}{F_{hw}}}},} & (11) \\{{T_{{cooling}\quad{coil}} = {2.0\frac{F_{air}}{F_{cw}}}},} & (12)\end{matrix}$where

T_(heating coil)—Time constant of the heating coil in seconds,

T_(cooling coil)—Time constant of the cooling coil in seconds,

F_(air)—Maximum or design air flow rate in liters per second,

F_(hw)—Maximum or design hot water flow rate in liters per second,

F_(cw)—Maximum or design chill water flow rate in liters per second.

2-Input-1-Output (2×1) MFA Control System for Air Handling Unit AHU withNo Cooling Coil

FIG. 5 is a block diagram illustrating a 2-input-1-output (2×1) MFAcontrol system that comprises a 1-input-2-output (1×2) model-freeadaptive (MFA) controller 244, a 2-input-1-output (2×1) supply airtemperature process of the air handling unit 254, and signal adders 256,258. The supply air temperature process 254 further comprises a damper246, a heating actuator 248, a heating coil 250, and a temperaturesensor 252. This system is similar to the one described in FIG. 4 exceptthat there is no cooling actuator and cooling coil in this system. Thenthe time constant for the damper and heating process can be estimatedbased on the following formulas:T _(cd) =T _(damper actuator) +T _(heating coil) +T_(temp sensor,)  (13)T _(ch) =T _(heating actuator) +T _(heating coil) +T_(temp sensor,)  (14)where

T_(cd)—Damper process time constant,

T_(ch)—Heating process time constant,

T_(damper actuator)≈30 seconds,

T_(heating actuator)≈30 seconds,

T_(temp sensor)≈30 seconds,

T_(heating coil) can be calculated based on Equations (9) or (11).

AHU with No Heating Coil

FIG. 6 is a block diagram illustrating a 2×1 MFA control system thatcomprises a 1×2 MFA controller 260, a 2×1 supply air temperature processof the air handling unit 270, and signal adders 272, 274. The supply airtemperature process 270 further comprises a damper 262, a coolingactuator 264, a cooling coil 266, and a temperature sensor 268. Thissystem is similar to the one described in FIGS. 1, 2 and 4 except thatthere is no heating actuator and heating coil in this system. Then thetime constant for the damper and cooling process can be estimated basedon the following formulas:T _(cd) =T _(damper actuator) +T _(cooling coil) +T_(temp sensor),  (15)T _(cc) =T _(cooling actuator) +T _(cooling coil) +T_(temp sensor),  (16)where

T_(cd)—Damper process time constant,

T_(cc)—Cooling process time constant,

T_(damper actuator)≈30 seconds,

T_(cooling actuator)≈30 seconds,

T_(temp sensor)≈30 seconds,

T_(cooling coil) can be calculated based on Equations (10) or (12).

AHU with Fixed Damper

FIG. 7 is a block diagram illustrating a 2×1 MFA control system thatcomprises a 1×2 MFA controller 276, a 2×1 supply air temperature processof the air handling unit 288, and signal adders 290, 292. The supply airtemperature process 288 further comprises a heating actuator 278, acooling actuator 280, a heating coil 282, a cooling coil 284, and atemperature sensor 286. This system is similar to the one described inFIG. 2 except that the damper or the mixed air dampers have fixedpositions so that they are not part of the automatic control system.Then the time constant for the heating and cooling process can beestimated based on the following formulas:T _(ch) =T _(heating actuator) +T _(heating coil) +T _(cooling coil) +T_(temp sensor),  (17)T _(cc) =T _(cooling actuator) +T _(cooling coil) +T_(temp sensor),  (18)where

T_(ch)—Heating process time constant,

T_(cc)—Cooling process time constant,

T_(heating actuator)≈30 seconds,

T_(cooling actuator)≈30 seconds,

T_(temp sensor)≈30 seconds,

T_(heating coil) can be calculated based on Equations (9) or (11).

T_(cooling coil) can be calculated based on Equations (10) or (12).

Single-Input-Single-Output (SISO) MFA Control System for Air HandlingUnit

In U.S. Pat. No. 6,055,524 and U.S. Pat. No. 6,556,980,single-input-single-output (SISO) model-free adaptive (MFA) controlsystems are described. An SISO MFA controller can be applied to controlthe single-input-single-output processes in an air handling unitincluding

Supply air temperature (damper, heating process, or cooling process),

Mixed air temperature,

Duct static pressure,

Air flow,

Humidity inner loop (duct air discharge flow), and

Humidity outer loop (return air flow).

As illustrated in FIG. 6, a SISO MFA control system comprises a SISO MFAcontroller 294, a SISO process 302, and signal adders 304, 306. The SISOprocess further comprises an actuator 296, a sub-process 298, and asensor 300. The signals shown in FIG. 6 are as follows:

r(t)—Setpoint.

y(t)—Process Variable, y(t)=x(t)+d(t).

x(t)—SISO Process Output.

u(t)—Controller Output.

d(t)—Disturbance, the disturbance caused by noise or load changes.

e(t)—Error between the Setpoint and Process Variable, e(t)=r(t)−y(t).

The control objective is for the controller to produce an output u(t) tomanipulate the actuator so that the process variable y(t) tracks thegiven trajectory of its setpoint r(t) under variations of setpoint,disturbance, and process dynamics.

For a standard SISO MFA controller, there are only 2 importantcontroller parameters:

Controller gain, K_(c)

Process time constant, T_(c)

Since the MFA controller 294 is adaptive, the controller gain K_(c) canbe set using a default value and no manual tuning of this parameter isrequired after the controller 294 is launched. For instance, we can setK_(c)=3 as the default value when configuring the MFA controller 294. Onthe other hand, the time constant T_(c) needs to be set relativelyaccurately since it is related to the dynamic behavior of the process.As with the embodiments described above, the process time constant isestimated based on the size of the AHU system and type of the controlloop as listed in Table 1.

For the supply air temperature loops, the analysis and formulasdiscussed above in connection with FIGS. 4 through 7 are still valid. Insome cases, instead of the 1×3 or 1×2 MFA controllers discussed above,two or three SISO MFA controllers may be used to control the damper,heating, and cooling processes, individually. This, however, is not apreferred method since the control actions of these multiple SISOcontrollers may fight each other.

For the mixed air temperature loop, the process comprises a damper and atemperature sensor for measuring the mixed air temperature. Therefore,its time constant can be estimated based on the following formula:T _(c) =T _(damper actuator) +T _(temp sensor,)  (19)where

T_(damper actuator)≈30 seconds,

T_(temp sensor)≈30 seconds. TABLE 1 Loop Type System Size Time ConstantT_(c) in Seconds Supply Air Temp Use Equations Above Mixed Air Temp UseEquation Above Duct Static Pressure Small 6 Medium 10 Large 20 Air FlowSmall 6 Medium 10 Large 20 Humidity (Inner loop) Small 50 Medium 100Large 200 Humidity (Outer loop) Small 100 Medium 250 Large 500

The static pressure and air flow loops are relatively fast. The processtime constants can be estimated based on the size of the AHU system withonly 3 categories: small, medium, and large as shown in Table 1.

The humidity is controlled using a cascade control system where theinner loop is the duct discharge air flow and outer loop is the returnair flow. Humidity is a much slower process and the time constants forboth inner and outer loops can be estimated based on the size of the AHUsystem as well.

The above embodiments illustrate, among other things, that the timeconstant tc of an air handling unit (e.g. air handling units 108, 238,254, 270 and 288) for supply air temperature control is estimatedpreferably without requiring an actual bump test of the air handlingunit. In accordance with one aspect of the invention, the time constanttc of heating and cooling processes is estimated using physical dataregarding the heating and cooling coils, and in some cases usingassumptions for other elements.

Obtaining a gain estimate is not within the purview of this disclosure,and indeed may at present require conventional testing techniques.However, it is known that if adaptive controls are used, such as theadaptive MFA control taught by U.S. provisional application Ser. No.10/857,520, the gain estimate may be within a wide range. In thosecases, the control circuit itself adjusts and tunes the gain. In such anexample, an initial gain value may be three.

It will also be noted that in other embodiments of the invention, thetime constant of the heating and cooling coils such as heating andcooling coils 128, 130 of FIGS. 1 and 2 determined as described hereinmay be used for other purposes, and in other control schemes involvingthose elements.

An exemplary method according to the invention is a method ofestablishing a time constant for supply air control in an air handlingunit.

FIG. 9 shows an exemplary method of establishing a time constant for oneor more controlled processes that affect supply air temperature in anair handling unit. The operations of FIG. 9 are discussed in connectionwith the air handling unit 108 of FIGS. 1 and 2. However, it will beappreciated that the method is of general applicability, and indeed maybe used to generate the time constants in accordance with theembodiments of FIGS. 3-8, discussed above.

Referring to FIG. 9, in step 405, a select supply air temperaturecontrol operation of the air handling unit 108 is selected. The supplyair temperature control operations of the exemplary air handling unit108 of FIG. 1 include a damper process, which allows more warm or cooloutside air into the system, a heating coil process, which heats thesupply air using the heating coil 128, and a cooling coil process, whichcools the supply air using the cooling coil 130. The select controloperation may be defined by the actuator of the device that is beingcontrolled or manipulated. The device being actuated or manipulated isreferred to herein as the controlled device. Thus, the controlled devicemay be the dampers, the heating valve/coil, or the cooling valve/coil.It will be appreciated that there may be more or less operations andcontrolled devices in other cases.

In step 410, all active process devices between the controlled deviceand the feedback temperature sensor are identified. These devices arereferred to as the intermediate devices. The supply fan 112 need not beincluded as an intermediate device, regardless of its location, becauseit has a negligible time constant as a relative matter. Referring toFIG. 1, if the controlled device is the heating coil 128, then the onlyintermediate device is the cooling coil 130.

In step 415, the estimated time constant is calculated by adding thetime constants of the following elements together: the actuator of thecontrolled device; the controlled device itself; the intermediatedevices; and the temperature sensor. The sum of the time constants forthe above-listed elements is the estimated time constant TC_(est) forthe control operation. The time constants of the individual elements maybe estimates and/or numbers determined experimentally.

By way of non-limiting example, the time constant for valve actuators164, 168 and/or damper actuators 162 may constitute, or be derived from,the stroke time. The stroke time of an actuator is the time it takes forthe actuator to change from one extreme to the other extreme. The stroketime of an actuator may be obtained experimentally or obtained fromspecifications for the device. Many common actuators have stroke timesof on the order of 30 seconds.

Similarly, the temperature sensor time constant may be known, defined inthe specification for the device, or obtained experimentally. If no timeconstant-related information regarding the temperature sensor 156 isavailable, then a rough estimate of 30 seconds may be used.

In accordance with at least some embodiments of the present invention,the estimate of the cooling coil 130 and heating coil 128 time constantsis calculated based on a few, and in an advantageous embodiment, two,physical characteristics of the relevant coil. These two characteristicsinclude the maximum air flow rate through the coil (i.e. past theoutside surface of the heat exchange element of the coil) and themaximum liquid (coolant or hot water) flow rate through the interior ofthe coil.

It has been determined through experiments and testing that the timeconstant for a heating coil is given by:TC _(hc) =K _(hc) (F _(air) /F _(hc)),Where F_(air) is the maximum air flow through the coil and F_(hc) is themaximum liquid flow rate through the coil. The value K_(ch) is aconstant defined by a number of factors. The value K_(hc) of isadvantageously between about 0.01 and 0.02 when F_(air) and F_(hc) aregiven in terms of cubic feet per minute and gallons per minute,respectively. The value of 0.02 will tend to be more conservative andwill be less likely to contribute to instability. However, the responsetime of the system may suffer. The value of K_(hc) is advantageouslybetween 0.07 and 0.15 when F_(air) and F_(hc) are given in terms ofliters per second.

It has been determined through experiments and testing that the timeconstant for a heating coil is given by:TC _(cc) =K _(cc) (F_(air) /F _(cc)),Where F_(air) is the maximum air flow through the coil and F_(cc) is themaximum liquid flow rate through the coil. The value K_(cc) is aconstant, but may vary depending upon factors. The value K_(cc) of isadvantageously between about 0.12 and 0.25 when F_(air) and F_(cc) aregiven in terms of cubic feet per minute and gallons per minute,respectively. The value of 0.25 will tend to be more conservative andthus less likely to contribute to instability. Again, however, theresponse time of the system may suffer. The value of K_(cc) isadvantageously between 1.0 and 2.0 when F_(air) and F_(cc) are given interms of liters per second.

In step 420, the estimated time constant, which is the sum of timeconstants (estimated or actual) for the individual devices, is providedto and/or stored by the controller (i.e. stored at least temporarily).The control circuit 151 of the controller 150 may then use the timeconstant in its control algorithms for that particular process.Alternatively, the estimated time constant may be used by technician todevelop a suitable control algorithm which is later programmed into thecontroller 150. In either event, the controller 150 is either providedwith the estimated time constant TC_(est) itself, or is provided withcontrol information derived at least in part from the time constantTC_(est).

For example, if the time constant for the damper process is 78 seconds,then the PI, PID or MFA controller that generates the control output forthe damper actuator 162 uses a time constant of 78 seconds. In somecases the estimated time constant TC_(est) may be increased by a bufferamount to ensure system stability.

In one embodiment, the calculated time constant is provide as an initialvalue to an MFA controller. The MFA controller is also provided a gainfactor value of 3. The MFA controller may then operate to performcontrol operations using adaptive techniques as taught in U.S. patentapplication Ser. No. 10/857,520.

Three examples of the process of FIG. 4 are now described for the systemof FIGS. 1 and 2.

EXAMPLE 1 Cooling Coil Process

In step 405, a select control operation of the air handling unit 108 forwhich a time constant with be estimated is identified. In this example,the cooling coil process is identified. The cooling coil process is theprocess by which coolant is provided to the cooling coil 130 via thecooling valve actuator 168. The supply air flow passes through thecooling coil 130, and is cooled thereby.

In step 410, all devices between the controlled device and thetemperature sensor are identified. In this example, the controlleddevice is the cooling coil 130. The only device between the cooling coil130 and the temperature sensor 156 is the supply fan 112, which is notconsidered in determining the supply air temperature time constantestimates, as discussed further above. Accordingly, in this example,there are no intermediate devices.

In step 415, the estimated time constant is calculated by adding thetime constants of the actuator of the controlled device (cooling valveactuator 168), controlled device (the cooling coil 130), theintermediate devices (none), and the temperature sensor 156. The timeconstant of the cooling valve actuator 168, TC_(cv), is estimated at 30seconds, as discussed further above. The time constant of thetemperature sensor 156, TC_(ts) is also estimated at 30 seconds. Thetime constant of the cooling coil, TC_(cc), is given byTC _(cc)=0.25 (F_(air) /F _(cc)).In this example, it will be assumed that the maximum air flow F_(air) is15,000 cubic feet per minute, and the maximum fluid flow through thecooling coil 130 is 258 gallons per minute. In such a case, the timeconstant TC_(cc) is 14.5 seconds. Accordingly, the estimated timeconstant TC_(est) for the cooling coil process is:TC _(est)=30+30+14.5 or 74.5

In step 420, that cooling process time constant estimate is provided tothe control circuit 151, which uses the time constant for tuning itscontrol algorithms associated with cooling the supply air via thecooling coil 130.

EXAMPLE 2 Heating Coil Process

For this example, in step 405, the heating coil process is identified.The heating coil process is the process by which a heating medium (e.g.steam or water) is provided to the heating coil 128 via the heatingvalve actuator 164. The supply air flow passes through the heating coil128, and is heated thereby.

In step 410, all devices between the controlled device and thetemperature sensor are identified. In this example, the controlleddevice is the heating coil 128. Apart from the supply fan 112, the onlydevice that is between (i.e. within the flow stream between) the heatingcoil 128 and the temperature sensor 156 is the cooling coil 130. Becausethe supply fan 112 is not considered an intermediate device, the onlyintermediate device is the cooling coil 130 in this example.

In step 415, the estimated time constant is calculated by adding thetime constants of the actuator of the controlled device (heating valveactuator 164), controlled device (the heating coil 128), theintermediate device (cooling coil 130), and the temperature sensor 156.The time constant of the heating valve actuator 164, TC_(hv), isestimated at 30 seconds, as discussed further above. The time constantof the temperature sensor 156, TC_(ts) is again estimated at 30 seconds.The time constant of the heating coil, TC_(hc), is given byTC _(hc)=0.02 (F _(air) /F _(hc)).In this example, it will still be assumed that the maximum air flowF_(air) is 15,000 cubic feet per minute, and the maximum fluid flowthrough the heating coil 128 is 92 gallons per minute. In such a case,the time constant TC_(hc) is 3.26 seconds. As discussed above, the timeconstant of the cooling coil, TC_(hc), is given by TC_(hc)=0.25(F_(air)/F_(cc)), or 14.5 seconds.

Accordingly, the estimated time constant TC_(est) for the heating coilprocess is:TC _(est)=30+30+3.26+14.5, or 77.76

In step 420, that heating process time constant estimate is provided tothe control circuit 151, which uses the time constant for tuning itscontrol algorithms associated with heating the supply air via theheating coil.

EXAMPLE 3 Damper Process

In step 405, the damper process is identified. The damper processconsists of simultaneously moving the dampers 122, 124 and 126. When thedampers 124 and 126 are further closed and the damper 122 is furtheropened, more recirculated air is passed through the system and lessfresh air is passed through the system. If, in such a case, therecirculated air is cooler than the fresh air, then the supply airtemperature TS will tend to be reduced. The damper process relates tothe time constant for temperature changes to occur as a result ofchanges in the damper positions.

In step 410, all devices between the controlled device and thetemperature sensor are identified. In this example, the controlleddevice is the set of dampers 122, 124 and 126, which typically areoperated as a unit. Apart from the supply fan 112, the devices betweenthe dampers 122, 124, 126 and the temperature sensor 156 include thecooling coil 130 and heating coil 128. Accordingly, in this example, theintermediate devices consist only of the heating coil 128 and thecooling coil 130.

In step 415, the estimated time constant is calculated by adding thetime constants of the actuator of the controlled device (damperactuators 162), the controlled device (the dampers 122, 124, 126 do nothave an independent time constant), the intermediate devices (heatingcoil 128 and cooling coil 130), and the temperature sensor 156. The timeconstant of the damper actuators 162, TC_(d), is estimated at 30seconds, as discussed further above. The time constant of thetemperature sensor 156, TC_(ts) is again estimated at 30 seconds. Thetime constant of the cooling coil, TC_(cc), is given byTC _(cc)=0.25 (F _(air) /F _(cc)), which is 14.5 seconds as discussedabove.The time constant of the heating coil, TC_(hc), is given byTC _(hc)=0.02 (F _(air) /F _(cc)), which is 3.26 seconds as discussedabove.Accordingly, the estimated time constant TC_(est) for the damper processis:TC _(est)=30+30+14.5+3.26 or 77.76

In step 420, that damper process time constant estimate is provided tothe control circuit 151, which uses the time constant for tuning itscontrol algorithms associated with changing the temperature of thesupply air via the dampers 122, 124 and 126.

It will be appreciated that the above process may be adjusted for moreor less elements that affect the time constant of changing temperatureof the supply air.

It will further be appreciated that most or all of the steps of FIG. 9may be carried out by a portable or desktop computing device, or anyprocessing device that allows for the input of the system data.

For example, FIG. 10 shows an exemplary computing device 500 thatincludes a processing circuit 502 connected to a user interface 504, amemory 506 and an output 508 that is configured to generate timeconstants for use in a control device of an air handling unit such asthe air handling units 108, 238, 254, 270, 288 and 302 of FIGS. 1-8. Thecomputing device 500 may suitably be a general purpose personalcomputer, or a modified or specialized computing device. The processingcircuit 502 may suitably be a general purpose or special purposemicroprocessor or microcontroller and its accompanying circuitry. Theuser interface 504 may suitably include a keyboard, pointing device,voice interface, or the like, for receiving user input. The userinterface 504 preferably also includes a visible and/or audible display.

The memory 506 may suitably include a number of memory devices and/orcircuits, such as random access memory, read-only memory, disk drives,CD-ROM drives and any other memory capable of storing either programminginstructions, scratchpad data, and/or other data.

In an exemplary embodiment of the present invention, the memory 506stores program instructions that cause the processing circuit 502 tocarry out the process of FIG. 11 in order to generate a time constantfor one or more temperature changing processes of an air handling unit.It is contemplated that the operations of FIG. 11 would be executed asan air handling unit is being installed and its PID, PI or MFAcontroller is to be tuned.

Referring now to FIG. 11, the processing circuit 502 in step 605 causesthe user interface 504 to obtain input identifying a select operation ofthe air handling unit 108 for which a time constant is to be estimated.The select operation is defined by the actuator that is to bemanipulated. As discussed above, in a typical air handling unit such asthe air handling unit 108, there may be damper operation, a heating coiloperation, or a cooling coil operation. The processing circuit 502 mayindeed cause the user interface 504 to prompt the user to select betweenthe damper operation, the heating coil operation and the cooling coiloperation. The device corresponding to the selected operation isreferred to as the controlled device.

In step 610, the processing circuit 502 receives, via the user interface504, an identification of all devices between the controlled device andthe temperature sensor that measures the supply air temperature. Thesedevices are referred to as the intermediate devices. To this end, theprocessing circuit 502 may cause the user interface 504 to prompt theuser to answer in the affirmative or negative whether each of aplurality of possible intermediate devices is located between thecontrolled device an the temperature sensor. The user may thus enter,effectively, the appropriate configuration information relating to theselected process.

In step 615, the processing circuit 502 receives, via the user interface504, input information identifying the temperature sensor time constantthe actuator time constant for the actuator of the controlled device.The processing circuit 502 may suitably provide a default value of 30seconds, which the user may select if no time constant information isknown by the user. In an alternative, the processing circuit 502 mayprovide the user with Internet access or database access in order toattempt to obtain the time constant information from a database orwebsite, not shown, that maintains such information. To this end, theprocessing circuit 502 would be operable to connect to the Internet andexecute a web browser program.

In any event, in step 620, the processing circuit 502 receives, via theuser interface 504, input information identifying the maximum air flowrate through any coils that either constitute the controlled device oran intermediate device in the selected process. For example, theprocessing circuit 502 may receive information that a maximum of 15,000cubic feet per minute flows through the cooling coil, assuming thecooling coil is the controlled device. This value has been representedabove as F_(air).

In step 625, the processing circuit 502 receives, via the user interface504, input information identifying the maximum liquid flow rate throughany coils that either constitute an controlled device or an intermediatedevice in the selected process. These values may include F_(hc) for theheating coil and F_(cc) for the cooling coil.

In step 630, the processing circuit 502 calculates the device timeconstant for each coil that constitutes an intermediate device orcontrolled device. For each cooling coil, the processing circuit 502determines time constant of the cooling coil, TC_(cc), usingTC _(cc)=0.25 (F _(air) /F _(cc)).Similarly, for each heating coil, the processing circuit 502 determinesthe time constant of the heating coil, TC_(hc), usingTC _(hc)=0.02 (F _(air) /F _(cc)).

In step 635, the processing circuit 502 calculates the estimated timeconstant for the selected process adding the device time constantsobtained in steps 615 and 630.

In step 640, the processing circuit 502 either displays the estimatedtime constant obtained in step 635, provides the estimated time constantto a control circuit of the air handling unit, or both. In any event,the estimated time constant is at least temporarily stored in the memory506.

The control circuit of the air handling unit may then use the timeconstant in its control algorithms for that particular process. Theabove steps 605 to 635 may then be repeated for other control outputprocesses of the air handling unit.

It will be appreciated that the above described embodiments are merelyexemplary, and that those of ordinary skill in the art may readilydevise their own implementations and modifications that incorporate theprinciples of the present invention and fall within the spirit and scopethereof.

1. An arrangement comprising: a) a controller configured to control adevice within air handler unit, the air handler unit including at leasta first coil; b) a processing circuit configured to receive firstinformation representative of a maximum liquid flow rate through thefirst coil and second information representative of a maximum air flowrate of the first coil, the processing circuit further configured togenerate a time constant estimate, based on the first information andsecond information, for use in the controller in performing control ofthe device.
 2. The arrangement of claim 1, wherein the device includesan actuator for at least one from a group consisting of: one or moredampers, a heating coil, and a cooling coil.
 3. The arrangement of claim2, wherein the device comprises the coil.
 4. The arrangement of claim 1,wherein the device comprises the coil.
 5. The arrangement of claim 1,wherein the processing circuit is further configured to generate thetime constant estimate based at least in part on a time constant for atemperature sensor.
 6. The arrangement of claim 5, wherein theprocessing circuit is further configured to generate the time constantbased at least in part on a time constant for an actuator associatedwith the device.
 7. The arrangement of claim 1, wherein the processingcircuit is further configured to generate the time constant based atleast in part on a time constant for an actuator associated with thedevice.
 8. The arrangement of claim 1, wherein processing circuit isfurther configured to: generate a time constant estimate of the firstcoil as the value K (F_(air)/F_(c)), wherein K is a constant, F_(air) isthe maximum air flow rate past the first coil and F_(c) is the maximumliquid flow rate through the first coil; and generate the time constantestimate based at least in part on the time constant estimate of thefirst coil.
 9. The arrangement of claim 8, wherein the processingcircuit is further configured to generate the time constant estimatefurther based on a time constant estimate of a second coil.
 10. Thearrangement of claim 9, wherein the processing circuit is furtherconfigured to generate the time constant estimate of the second coilbased as the value K′ (F_(air)′/F_(c)′), wherein K′ is a constant,F_(air)′ is the maximum air flow rate past the second coil and F_(c)′ isthe maximum liquid flow rate through the second coil.
 11. Thearrangement of claim 10, wherein the processing circuit is furtherconfigured to generate the time constant estimate further based on atime constant estimate for a temperature sensor.
 12. The arrangement ofclaim 10, wherein the value of K is different than the value of K′. 13.A method comprising: a) determining a sequence of elements between afirst device and a supply air temperature sensor of an air handlingunit; b) obtaining an estimate for time constants associated with eachelement of the sequence; c) adding the time constants to obtain aprocess time constant estimate; and d) controlling a device based atleast in part on the process time constant estimate.
 14. The method ofclaim 13, wherein the sequence of elements includes at least one coiland step b) further comprises generating a time constant estimate forthe coil based on quantifiable physical characteristics of the coil. 15.The method of claim 14, wherein step b) further comprises generating thetime constant estimate of the coil using a maximum liquid flow ratethrough the coil.
 16. The method of claim 15, wherein step b) furthercomprises generating the time constant estimate of the coil using amaximum air flow rate past the coil.
 17. The method of claim 15, whereinb) further comprises generating the time constant estimate of the coilas the value K (F_(air)/F_(c)), wherein K is a constant, F_(air) is themaximum air flow rate past the coil and F_(c) is the maximum liquid flowrate through the coil.
 18. The method of claim 17, further comprisingusing a constant value for a time constant of the first device if thefirst device is an actuator, the time constant of the first device basedon a stroke time of the actuator.
 19. The method of claim 14, furthercomprising a constant value for a time constant of the first device ifthe first device is an actuator, the constant value of the first devicebased on a stroke time of the actuator.
 20. The method of claim 19,wherein step a) further comprises determining the sequence of elementssuch that at least a first element physically interposed between thefirst device and the supply air temperature element is excluded from thedetermined sequence of elements.
 21. A method comprising: a) obtainingan estimate for a supply air process time constant based at least inpart on physical specifications of devices disposed in a supply airpath; and b) controlling at least one element of an air handling unitbased at least in part on the process time constant estimate.
 22. Themethod of claim 21, further comprising obtaining estimates for timeconstants of a plurality of supply air processes.
 23. The method ofclaim 22, wherein step a) further comprises generating a first timeconstant T_(cd) for a damper process based on the followingrelationship:T _(cd) =T _(damper actuator) +T _(first coil) +T _(second coil) +T_(temp sensor), wherein T_(damper actuator) is a time constant estimatefor a damper actuator, T_(first coil) is a time constant estimate for afirst heating or cooling coil, T_(second coil) is a time constantestimate for a second heating or cooling coil, and T_(temp sensor) is atime constant estimate for a temperature sensor.
 24. The method of claim23, wherein step a) further comprises generating a first time constantT_(l) for a first coil process based on the following relationship:T _(l) =T _(first coil actuator) +T _(first coil) +T _(second coil) +T_(temp sensor), wherein T_(first coil actuator) is a time constantestimate for an actuator corresponding to the first heating or coolingcoil, T_(first coil) is a time constant estimate for the first heatingor cooling coil, T_(second coil) is a time constant estimate for thesecond heating or cooling coil, and T_(temp sensor) is a time constantestimate for a temperature sensor.
 25. The method of claim 23, whereinstep a) further comprises generating a first time constant T_(l) for afirst coil process based on the following relationship:T _(l) =T _(first coil actuator) +T _(first coil) +T _(temp sensor),wherein T_(first coil actuator) is a time constant estimate for anactuator corresponding to the first heating or cooling coil,T_(first coil) is a time constant estimate for the first heating orcooling coil, and T_(temp sensor) is a time constant estimate for atemperature sensor.
 26. The method of claim 22, wherein step a) furthercomprises generating a first time constant T_(l) for a first coilprocess based on the following relationship:T _(l) =T _(first coil actuator) +T _(first coil) +T _(temp sensor),wherein T_(first coil actuator) is a time constant estimate for anactuator corresponding to a first heating or cooling coil,T_(first coil) is a time constant estimate for the first heating orcooling coil, and T_(temp sensor) is a time constant estimate for atemperature sensor.
 27. The method of claim 26, wherein step a) furthercomprises generating the value T_(first coil) using the followingrelationshipT _(first coil=)0.02(F _(air) /F _(hw)), wherein F_(air) is the maximumor design air flow rate in cubic feet per minute, and F_(hw) is themaximum or design hot water flow rate in gallons per minute.
 28. Themethod of claim 26, wherein step a) further comprises generating thevalue T_(first coil) using the following relationshipT _(first coil)=0.25(F _(air) /F _(cw)), wherein F_(air) is the maximumor design air flow rate in cubic feet per minute, and F_(cw) is themaximum or design chill water flow rate in gallons per minute.